Yamaha YZFR1W 2007, Service Manual

Page 1: ...2007 MOTORCYCLE SERVICE MANUAL Model YZFR1W 4C8281972000 4C8281972000...

Page 2: ...ZFR1W SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition October 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly...

Page 3: ...ded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of it...

Page 4: ...ge 1 Sub section titles appear in smaller print than the section title 2 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly sec...

Page 5: ...ounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grea...

Page 6: ...FEATURES 1 2 FI SYSTEM 1 3 IMPORTANT INFORMATION 1 12 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 12 REPLACEMENT PARTS 1 12 GASKETS OIL SEALS AND O RINGS 1 12 LOCK WASHERS PLATES AND COTTER PINS 1 12 BE...

Page 7: ...S20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS20150 MODEL LABEL The model label 1 is affixed to the frame This in...

Page 8: ...ecomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place...

Page 9: ...osition sensor for throttle cable pulley crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant tem perature sensor atmospheric pressure sensor cylinder identifica...

Page 10: ...easy to use torque even in a high revving engine The YCC I system calculates the value from the engine revolution number and throttle opening rate activates the intake air funnel with the electronic...

Page 11: ...ractical use range Intake pipe length switching control using the motor The intake pipe length switching operation in a minute time is now available by means of the motor drive using the electronic co...

Page 12: ...CPU 32 bit 8 Throttle servo motor driver 9 Throttle servo motor driver operation sens ing shut off circuit 10 Throttle servo motor driver operation sensing feedback emergency stop 11 Emergency stop 12...

Page 13: ...al switch 7 Atmospheric pressure sensor 8 Accelerator position two signals 9 Throttle position two signals 10 Engine revolution 11 Vehicle speed 12 Coolant temperature 13 Neutral In gear 14 Atmospheri...

Page 14: ...eter and odometer tripmeter displays between kilometers and miles press the SELECT button for at least one second Tachometer The electric tachometer allows the rider to monitor the engine speed and ke...

Page 15: ...lay to the stopwatch mode select it by pushing the SELECT button The stopwatch digits will start flashing Release the SELECT button and then push it again for a few seconds until the stopwatch digits...

Page 16: ...flash and then the display will indicate a two digit error code NOTE If the display indicates error code 52 this could be caused by transponder interference If this error code appears try the followi...

Page 17: ...ht flashes four times per second The indicator light is deactivated in other words it will not come on or flash This setting is selected when the indicator light flashes once every two seconds 2 Push...

Page 18: ...correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha...

Page 19: ...rease Oil bearings liberally when installing if appropriate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces EAS20240 CIRCLIPS Before reassemb...

Page 20: ...times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5 C...

Page 21: ...pending on the country When placing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number star...

Page 22: ...0890 01423 Damping rod holder YM 01423 4 53 4 54 Oil filter wrench 90890 01426 YU 38411 3 12 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 52 4 57 Rod puller 90890 01437 Universal d...

Page 23: ...ring compressor 90890 01441 YM 01441 4 52 4 57 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 55 Vacuum gauge 90890 03094 Carburetor synchronizer YU 44456 3 7 Compression...

Page 24: ...adapter 22 mm YM 04108 5 23 5 29 Middle driven shaft bearing driver 90890 04058 Bearing driver 40 mm YM 04058 6 11 Mechanical seal installer 90890 04078 Water pump seal installer YM 33221 A 6 11 Unive...

Page 25: ...installer 4 5 mm YM 04117 5 25 Valve guide reamer 5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 25 Valve guide reamer 4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 25 Ignition checker 908...

Page 26: ...8 89 8 90 8 91 8 92 8 93 8 94 8 95 8 96 8 97 8 97 8 98 8 99 8 100 Oil pressure adapter H 90890 03139 3 13 Valve lapper 90890 04101 Valve lapping tool YM A8998 3 5 Fuel pressure adapter 90890 03176 YM...

Page 27: ...SPECIAL TOOLS 1 21 Ring nut wrench 90890 01507 YM 01507 4 68 4 70 Damper rod holder 22 mm 90890 01365 4 69 4 70 Tool name Tool No Illustration Reference pages...

Page 28: ...RQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 20 ENGINE 2 20 CHASSIS 2 20 LUBRICATION...

Page 29: ...ns Overall length 2060 mm 81 1 in Overall width 720 mm 28 3 in Overall height 1110 mm 43 7 in Seat height 835 mm 32 9 in Wheelbase 1415 mm 55 7 in Ground clearance 135 mm 5 31 in Minimum turning radiu...

Page 30: ...ment 3 10 L 3 28 US qt 2 73 Imp qt Oil filter Oil filter type Formed Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 010 0 100 mm 0 0004 0 0039 in Limit 0 18 mm 0 0071 in Ou...

Page 31: ...Limit 34 350 mm 1 3524 in Intake B 25 170 25 270 mm 0 9909 0 9949 in Limit 25 070 mm 0 9870 in Exhaust A 33 550 33 650 mm 1 3209 1 3248 in Limit 33 450 mm 1 3169 in Exhaust B 25 192 25 292 mm 0 9918...

Page 32: ...ameter exhaust 4 500 4 512 mm 0 1772 0 1776 in Limit 4 550 mm 0 1791 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide cl...

Page 33: ...iston Piston to cylinder clearance 0 010 0 035 mm 0 0004 0 0014 in Limit 0 12 mm 0 0047 in Diameter D 76 975 76 990 mm 3 0305 3 0311 in Height H 12 0 mm 0 47 in Offset 0 50 mm 0 0197 in Offset directi...

Page 34: ...c Clutch release method Outer pull rack and pinion pull Clutch lever free play 10 0 15 0 mm 0 39 0 59 in Friction plate thickness 2 90 3 10 mm 0 114 0 122 in Wear limit 2 80 mm 0 1102 in Plate quantit...

Page 35: ...perage 6 0 A Output pressure 324 0 kPa 46 1 psi 3 24 kgf cm Fuel injector Model quantity 297500 1110 4 Manufacturer DENSO Throttle body Type quantity 45EIDW 1 Manufacturer MIKUNI ID mark 4C81 00 Throt...

Page 36: ...RELLI DIABLO CORSA L Manufacturer model MICHELIN Pilot POWER Wear limit rear 0 8 mm 0 03 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm...

Page 37: ...l damper Front fork travel 120 0 mm 4 72 in Fork spring free length 237 5 mm 9 35 in Limit 232 8 mm 9 17 in Collar length 100 0 mm 3 94 in Installed length 223 0 mm 8 78 in Spring rate K1 9 07 N mm 51...

Page 38: ...circuit Model manufacturer FH012AA SHINDENGEN Regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Battery Model YTZ10S Voltage capacity 12 V 8 6 Ah Specific gravity 1 3...

Page 39: ...tance 4 18 4 62 Horn Horn type Plane Quantity 1 pcs Model manufacturer YF 12 NIKKO Maximum amperage 3 0 A Coil resistance 1 15 1 25 Performance 105 113 dB 2m Turn signal relay Relay type Full transist...

Page 40: ...l To avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 41: ...olt water pump side M6 1 10 Nm 1 0 m kg 7 2 ft lb Water pump inlet pipe bolt front side M6 1 10 Nm 1 0 m kg 7 2 ft lb Oil water pump drive sprocket bolt M6 1 15 Nm 1 5 m kg 11 ft lb Water pump bolt M6...

Page 42: ...nkcase stud bolt M10 10 8 0 Nm 0 8 m kg 5 8 ft lb Crankcase bolt main journal M9 10 See NOTE Crankcase bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Crankcase bolt M8...

Page 43: ...or cover screw M6 3 10 Nm 1 0 m kg 7 2 ft lb Thermostat assembly stay bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter clutch idler gear bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Clutch boss nut M20 1 115 Nm 11 5...

Page 44: ...st tighten the bolts to approximately 20 Nm 2 0 m kg 14 ft lb with a torque wrench follow ing the tightening order 2 Loosen all the bolts one by one following the tightening order and then tighten the...

Page 45: ...m 0 5 m kg 3 6 ft lb Under cowling and engine bolt M6 3 5 0 Nm 0 5 m kg 3 6 ft lb Rear view mirror nut M6 4 7 0 Nm 0 7 m kg 5 1 ft lb Front cowling and intake air duct panel screw M5 2 1 3 Nm 0 13 m k...

Page 46: ...1 ft lb Fuel tank bolt rear M6 4 7 0 Nm 0 7 m kg 5 1 ft lb Fuel tank side cover screw M5 2 4 0 Nm 0 4 m kg 2 9 ft lb Rider seat bolt M6 2 7 0 Nm 0 7 m kg 5 1 ft lb Seat lock assembly bolt M6 2 10 Nm...

Page 47: ...of the axle circumference is positioned on the end face of the fork At this stage it can be accepted if the end face of the axle becomes partially concave to the end face of the fork 4 In the order fr...

Page 48: ...Clutch pull rod Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork g...

Page 49: ...Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber Seat lock assembly moving parts Sidestand pivoting pint and metal to metal moving parts Link and sid...

Page 50: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22...

Page 51: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART...

Page 52: ...r 2 Oil pump 3 Relief valve 4 Oil cooler 5 Oil filter 6 Main gallery 7 AC magneto drive gear shower 8 Shift fork upper 9 Main axle 10 Mission shower 11 Drive axle 12 AC magneto axle 13 Piston cooler 1...

Page 53: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20410 LUBRICATION DIAGRAMS...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Intake camshaft 2 Exhaust camshaft 3 Oil filter cartridge 4 Oil level switch...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Relief valve 6 Oil pipe 7 Oil strainer 8 Oil pump...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter cartridge 2 Oil level switch 3 Oil pump 4 Oil strainer 5 Oil pipe 6 Oil cooler...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 A A A A...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Main axle 2 Oil delivery pipe 3 Drive axle...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Cylinder head 2 Crankshaft...

Page 63: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS...

Page 64: ...COOLING SYSTEM DIAGRAMS 2 36 1 Water pump 2 Radiator 3 Radiator fan...

Page 65: ...COOLING SYSTEM DIAGRAMS 2 37...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 38 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat...

Page 67: ...CABLE ROUTING 2 39 EAS20430 CABLE ROUTING...

Page 68: ...e to insert the coupler and boot to the stay hole D The speedometer lead should not be strained E To the headlight stay hole F Route by the rear side of the vehicle away from the right auxiliary light...

Page 69: ...CABLE ROUTING 2 41...

Page 70: ...etween 0 and 20 mm 0 and 0 79 in from the split of the under bracket G Clamp the leads inside the front fork of the vehicle Point the exit of the horn lead to the left front fork side H Fit in the cla...

Page 71: ...CABLE ROUTING 2 43...

Page 72: ...drain hose with the radiator bottom end Fasten the clutch cable and coolant reser voir drain hose with a clamp G To the engine H Clamp the coolant reservoir drain hose to the lower side of the vehicle...

Page 73: ...CABLE ROUTING 2 45...

Page 74: ...lead through the clamp G To the EXUP servo motor H Pass the fuel tank drain hose and fuel tank breather hose through the hole of the cover from the outside of the water pipe after passing the water h...

Page 75: ...CABLE ROUTING 2 47...

Page 76: ...ft position sensor lead with a clamp N All hoses and leads should be routed over the vehicle s upper side above the heat protector O To the fuel pump P To the speed sensor Q Clamp the wire harness win...

Page 77: ...CABLE ROUTING 2 49...

Page 78: ...cle and clamp at the junction of the wire harness Fasten the battery negative lead wire har ness and starter motor lead with a clamp B Point the tip of the clamp excessive part to the inside of the ve...

Page 79: ...CABLE ROUTING 2 51...

Page 80: ...til the click sound is heard and check that the connector does not come off Make sure that no foreign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equival...

Page 81: ...CABLE ROUTING 2 53...

Page 82: ...ADJUSTING THE EXUP CABLES 3 17 CHECKING THE EXUP SERVO MOTOR 3 18 CHECKING THE COOLANT LEVEL 3 18 CHECKING THE COOLING SYSTEM 3 19 CHANGING THE COOLANT 3 19 CHASSIS 3 22 ADJUSTING THE FRONT DISC BRAKE...

Page 83: ...THE SIDESTAND 3 35 LUBRICATING THE REAR SUSPENSION 3 35 ELECTRICAL SYSTEM 3 36 CHECKING AND CHARGING THE BATTERY 3 36 CHECKING THE FUSES 3 36 REPLACING THE HEADLIGHT BULBS 3 36 ADJUSTING THE HEADLIGHT...

Page 84: ...l hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 13000 km 8000 mi or 12 months Replace Replace 3 Valve clearance Check and adjust valv...

Page 85: ...nd fasteners Correct if necessary 14 Brake and clutch lever pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Shift pedal rod pivots Apply lithium soap based grease all purpos...

Page 86: ...rvoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or dama...

Page 87: ...INDUCTION SYSTEM on page 7 9 Radiator Radiator fan motor Refer to RADIATOR on page 6 1 2 Remove Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5...

Page 88: ...er the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the...

Page 89: ...e Install the new valve pad 1 and the valve lifter 2 NOTE Lubricate the valve pad with molybdenum disulfide grease Lubricate the valve lifter with molybdenum disulfide oil The valve lifter must turn...

Page 90: ...ose 5 Install Fuel tank Refer to FUEL TANK on page 7 1 6 Start the engine and let it warm up for sev eral minutes 7 Check Engine idling speed 8 Adjust Throttle body synchronization Basic procedure a S...

Page 91: ...ndard turn out the bypass air screws of the other throttle bod ies to adjust them NOTE Do not turn out the bypass air screw of the throttle body with the lowest vacuum pres sure After each step rev th...

Page 92: ...s 4 Remove Spark plugs CAUTION ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 5 Check...

Page 93: ...ion 6 Measure Compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compres sion gauge st...

Page 94: ...o enter the crankcase 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again NOTE Before checking the engine oil level wait a few minutes until the o...

Page 95: ...heck Engine oil drain bolt gasket 8 Install Engine oil drain bolt along with the gasket 9 Fill Crankcase with the specified amount of the recom mended engine oil 10 Install Engine oil filler cap Lower...

Page 96: ...ery bolt 1 WARNING EWA12980 The engine muffler and engine oil are extremely hot 4 Install Oil pressure gauge 1 Adapter 2 5 Measure Engine oil pressure at the following conditions Out of specification...

Page 97: ...the specified clutch cable free play is obtained c Tighten the locknuts 1 EAS20960 REPLACING THE AIR FILTER ELEMENT 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank side covers Fuel...

Page 98: ...ing the air filter element into the air filter case cover make sure that the sealing surfaces are aligned to prevent any air leaks 6 Install Fuel tank Fuel tank side covers Refer to FUEL TANK on page...

Page 99: ...amage Replace Loose connection Connect properly CAUTION ECA13450 Make sure the crankcase breather hose is routed correctly 3 Install Fuel tank Fuel tank side covers Refer to FUEL TANK on page 7 1 Ride...

Page 100: ...a 5 Adjust EXUP cable free play a Turn the main switch to ON b Check the EXUP pulley position c Projection of the EXUP pulley position is between 1 and 2 d Loosen the both locknuts 3 e Turn the both...

Page 101: ...mes EAS21110 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand Make sure the vehicle is upright 2 Remove Lower cowlings Right side cowling Re...

Page 102: ...ve Coolant reservoir Coolant reservoir hose 3 Disconnect Coolant reservoir cap 1 4 Drain Coolant from the coolant reservoir 5 Remove Radiator cap 2 WARNING EWA13030 A hot radiator is under pressure Th...

Page 103: ...ECA13480 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Us...

Page 104: ...for several minutes and then stop it 17 Check Coolant level Refer to CHECKING THE COOLANT LEVEL on page 3 18 NOTE Before checking the coolant level wait a few minutes until the coolant has settled 18...

Page 105: ...y an accident Therefore check and if necessary bleed the brake system CAUTION ECA13490 After adjusting the brake lever position make sure there is no brake drag EAS21190 ADJUSTING THE REAR DISC BRAKE...

Page 106: ...uids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a har...

Page 107: ...k Brake hose Brake fluid leakage Replace the dam aged hose Refer to FRONT BRAKE on page 4 20 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose cl...

Page 108: ...erably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose hav...

Page 109: ...AS21410 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain CAUTION ECA13550 A drive chain that is too tight will overload the engine and othe...

Page 110: ...chain since they may contain sol vents that could damage the O rings EAS21500 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the veh...

Page 111: ...aligned h Install the lock washer 1 NOTE Make sure the lock washer tabs a sit correctly in the ring nut slots b 5 Install Upper bracket Refer to STEERING HEAD on page 4 59 6 Measure Steering head tens...

Page 112: ...scratches Replace Oil seal 2 Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front...

Page 113: ...i tions Minimum 8 Standard 5 Maximum 0 Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Rebound damping adjust posi tions Min...

Page 114: ...e adjusting ring with the stopper 2 Rebound damping CAUTION ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Rebound damping a Turn the adjusting knob 1 in direction a or...

Page 115: ...g procedure applies to both of the tires 1 Check Tire pressure Out of specification Regulate Direction a Compression damping is increased suspension is harder Direction b Compression damping is decrea...

Page 116: ...the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is...

Page 117: ...RNING EWA13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has been changed or replaced always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The followin...

Page 118: ...D Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspen...

Page 119: ...ht bulb WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headligh...

Page 120: ...t beam vertically a Turn the adjusting screw 1 in direction a or b 3 Adjust Headlight beam horizontally a Turn the adjusting knob 2 in direction a or b Left headlight Right headlight 4 Install Front c...

Page 121: ...26 REMOVING THE FRONT BRAKE CALIPERS 4 27 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 28 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPE...

Page 122: ...TEERING HEAD 4 61 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER 4 64 DISPOSING OF A REAR SHOCK ABSORBER 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 CHECKING THE REAR SHOCK...

Page 123: ...b Parts to remove Q ty Remarks 1 Rider seat 2 Passenger seat 1 3 Battery negative lead 1 4 Battery positive lead 1 5 ECU engine control unit 1 6 ECU lead coupler 1 Disconnect 7 ECU cover 1 8 Battery b...

Page 124: ...turn signal light lead coupler 2 Disconnect 4 Lower cowling 2 5 Lower cowling front cover 1 6 Intake air duct panel 2 7 Intake air temperature coupler 1 Disconnect 8 Meter assembly coupler 1 Disconnec...

Page 125: ...enger seat Refer to GENERAL CHASSIS on page 4 1 Muffler Refer to ENGINE REMOVAL on page 5 1 1 Upper tail cover 1 2 Tail brake light lead coupler 1 Disconnect 3 Turn signal light licence plate light le...

Page 126: ...fer to FUEL TANK on page 7 1 1 Air filter case cover 1 2 Air filter 1 3 Intake funnel servo motor rod assembly 1 4 Intake funnel joint 2 5 Intake funnel 2 6 Intake funnel rod 2 7 Bushing 2 5 8 Air ind...

Page 127: ...fter assembly make sure that the intake funnel smoothly moves to the contacting surface between upper stopper and lower seating position when it is moved by hand Make sure that the intake funnel smoot...

Page 128: ...nostic mode and select the diagnostic code number 34 Refer to FUEL INJECTION SYSTEM on page 8 29 b Set the engine stop switch to c Check that the intake funnel operate smoothly strokes from the upper...

Page 129: ...h a screwdriver then pull the fastener out EAS21850 INSTALLING THE COVER 1 Install Rear fender Tail cover NOTE To install the quick fastener push its pin so that it protrudes from the fastener head th...

Page 130: ...3 Left brake hose holder 1 4 Right brake hose holder 1 5 Left front brake caliper 1 6 Right front brake caliper 1 7 Front wheel axle pinch bolt 4 8 Front wheel axle bolt 1 9 Front wheel axle 1 10 Coll...

Page 131: ...ONT WHEEL 4 9 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal left and right 2 2 Wheel bearing left and right 1 3 Spacer 1 For assembly reverse the disassembly pro cedu...

Page 132: ...FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel axle 2 Check Tire Front wheel Damage wear Replace Refer to...

Page 133: ...djust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot NOTE Place the front wheel on a suitable balancing stand a Spin the front...

Page 134: ...plies to both of the brake discs 1 Lubricate Wheel axle Oil seal lips 2 Lift the wheel up between the fork legs 3 Insert the wheel axle NOTE Install the tire and wheel with the mark 1 pointing in the...

Page 135: ...ONT WHEEL 4 13 WARNING EWA13490 Make sure the brake cable is routed prop erly NOTE Make sure that there is enough space between the brake pads before installing the brake cali pers on to the brake dis...

Page 136: ...1 Rear brake caliper 1 2 Locknut left and right 2 Loosen 3 Adjusting bolt left and right 2 Loosen 4 Rear wheel axle nut 1 5 Washer 1 6 Rear wheel axle 1 7 Left adjusting block 1 8 Right adjusting bloc...

Page 137: ...cket Order Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Dust cover 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Re...

Page 138: ...EAR WHEEL 4 16 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedur...

Page 139: ...t 2 4 Remove Wheel axle nut 1 Wheel axle Rear wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove Left collar 1 Rear wheel drive hub 2 Rear wheel dr...

Page 140: ...g nuts in stages and in a crisscross pattern EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the re...

Page 141: ...NG EWA13500 Make sure the brake hose is routed prop erly Rear wheel axle nut 150 Nm 15 0 m kg 108 ft lb Rear brake caliper bolt front side 27 Nm 2 7 m kg 20 ft lb Rear brake caliper bolt rear side 22...

Page 142: ...ng the front brake pads Order Job Parts to remove Q ty Remarks 1 Brake hose holder 1 2 Front brake caliper 1 3 Brake pad clip 4 4 Brake pad pin 2 5 Brake pad spring 2 6 Brake pad 4 7 Bleed screw 1 For...

Page 143: ...cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch lead conn...

Page 144: ...22 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Brake master cylinder body 1 For assembly reverse the disassemb...

Page 145: ...e calipers Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For inst...

Page 146: ...ake calipers Order Job Parts to remove Q ty Remarks 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 2 4 Brake pad 4 5 Brake caliper piston 6 6 Brake caliper piston seal 12 7 Bleed screw 1 For...

Page 147: ...S The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEEL on page 4 8 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specificati...

Page 148: ...en replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove Brake hose holder 1 Brake caliper 2 2 Remove Brake pad clips 1 Brake pad pins 2...

Page 149: ...iper 7 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 23 8 Check Brake lever operation Sof...

Page 150: ...tons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly Brake caliper body 3 Cracks damage Replace the brake cali per...

Page 151: ...rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical react...

Page 152: ...s 4 NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove Brake master cylinder holder Brake master cylinder EAS22510 CHECKING TH...

Page 153: ...he lower bolt There should be 2 2 5 mm 0 08 0 10 in of clearance between the right handlebar switch and the brake master cylinder holder 2 Install Copper washers Brake hose Union bolt WARNING EWA13530...

Page 154: ...servoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean...

Page 155: ...oving the rear brake pads Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Rear brake caliper 1 4 Brake pad shim 4 5 Brake pad 2 6 Bleed screw 1 7 Brake pad spring 1 For insta...

Page 156: ...page 3 25 1 Footrest plate 1 2 Brake fluid reservoir cap 1 3 Rear brake fluid reservoir diaphragm holder 1 4 Rear brake fluid reservoir diaphragm 1 5 Brake fluid reservoir tank 1 6 Brake fluid reserv...

Page 157: ...Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Hose joint 1 3 Bush 1 4 Brake master cylinder body 1 For assembly reverse the disass...

Page 158: ...calipers Order Job Parts to remove Q ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For insta...

Page 159: ...pers Order Job Parts to remove Q ty Remarks 1 Screw plug 1 2 Brake pad pin 1 3 Brake pad 2 4 Brake pad shim 4 5 Brake pad spring 1 6 Brake caliper piston 1 7 Brake caliper piston seal 2 8 Bleed screw...

Page 160: ...KING THE REAR BRAKE DISC 1 Remove Rear wheel Refer to REAR WHEEL on page 4 14 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc defl...

Page 161: ...ew d Install a new brake pad shim 3 onto each new brake pad 4 5 Install Brake pad pin Screw plug Brake caliper 6 Check Brake fluid level Below the minimum level mark a Add the recommended brake fluid...

Page 162: ...NG EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton c Remove the brak...

Page 163: ...ion Refer to CABLE ROUTING on page 2 39 CAUTION ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Brake...

Page 164: ...Check Brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Union bol...

Page 165: ...sure safe vehicle operation Refer to CABLE ROUTING on page 2 39 CAUTION ECA14160 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a as show...

Page 166: ...lways clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 25 4 Check Brake fluid level Below the minimum level mark a Add the recomme...

Page 167: ...1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Clutch cable 1 6 Clutch lever holder 1 7 Throttle cable housing 1 8 Throttle cable 2 9 Throttle grip 1 10 Front brake light switch...

Page 168: ...osen 19 Upper bracket pinch bolt 2 Loosen 20 Steering stem nut 1 Loosen 21 Upper bracket 1 22 Left handlebar 1 23 Right handlebar 1 For installation reverse the removal proce dure Removing the handleb...

Page 169: ...r as this may dangerously weaken it EAS22900 INSTALLING THE HANDLEBARS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling ove...

Page 170: ...the handlebar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rubber adhesive has fully dried...

Page 171: ...HANDLEBARS 4 49...

Page 172: ...WHEEL on page 4 8 Front brake caliper Refer to FRONT BRAKE on page 4 20 Side cowling Refer to GENERAL CHASSIS on page 4 1 1 Front fender 1 2 Handlebar pinch bolt 1 Loosen 3 Upper bracket pinch bolt 1...

Page 173: ...1 3 Damper adjusting rod 1 4 Damper adjusting rod locknut 1 5 Washer 1 6 Spacer 1 7 Fork spring 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal 1 11 Washer 1 12 Damper rod assembly bolt 1 13 Copper was...

Page 174: ...loosening the upper and lower bracket pinch bolts support the front fork leg 4 Remove Front fork leg EAS22990 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front for...

Page 175: ...inner tube as this may dangerously weaken it 2 Measure Spring free length a Out of specification Replace 3 Check Damper rod assembly 1 Damage wear Replace Obstruction Blow out all of the oil pas sages...

Page 176: ...components are clean 1 Install Damper rod assembly 1 Inner tube 2 Damper rod assembly bolt Cooper washer WARNING EWA4C81002 Always use new copper washer CAUTION ECA14210 Allow the damper rod assembly...

Page 177: ...ver the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Washer Oil seal 1 with the fork seal driver 2 6 Install Oil seal clip 1 NOTE Adjust the oil s...

Page 178: ...troke the damper rod slowly because the fork oil may spurt out 11 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to blee...

Page 179: ...h Install the nut 1 and position it as speci fied b i Set the cap bolt distance c to specifica tion j Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt k Hold the cap...

Page 180: ...acket pinch bolts 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Handlebar pinch bolt 3 Upper bracket pinch bolt 4 WARNING EWA13680 Make sure the brake hoses are routed prop erly 3 Adjust Spring prel...

Page 181: ...t fork legs Refer to FRONT BRAKE on page 4 20 Handlebar Refer to HANDLEBARS on page 4 45 1 Main switch lead coupler 2 Disconnect 2 Upper bracket bolt 2 3 Left handlebar assembly 1 4 Right handlebar as...

Page 182: ...ing cover 1 18 Bearing inner race 2 19 Upper bearing 1 20 Lower bearing 1 21 Dust seal 1 22 Bearing outer race 2 For installation reverse the removal proce dure Removing the lower bracket Order Job Pa...

Page 183: ...he bearing races 1 from the steering head pipe with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearin...

Page 184: ...AND ADJUSTING THE STEERING HEAD on page 3 27 3 Install Upper bracket Steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to INSTALLING THE FRONT FORK LEGS...

Page 185: ...ENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 1 4 Self locking nut 1 5 Rear shock absorber ass...

Page 186: ...through the rear shock absorber at a point 15 20 mm from its end as shown WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK...

Page 187: ...INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate Collars Bearings 2 Install Rear shock absorber assembly NOTE Install the connecting arm front bolt from the left 3 Tighten Rear shock absorber...

Page 188: ...RBER ASSEMBLY on page 4 63 Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Right footrest bracket 1 2 Drive chain adjusting bolt locknut 2 2 3 Drive chain guard 1 4 Rear fender 1 5 Brake hose hol...

Page 189: ...SWINGARM 4 67 For installation reverse the removal proce dure Removing the swingarm Order Job Parts to remove Q ty Remarks...

Page 190: ...sure the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vert...

Page 191: ...n a bent pivot shaft 3 Wash Pivot shaft Dust covers Spacer Washers Bearings 4 Check Dust covers 1 Spacer 2 Washer 3 Damage wear Replace Bearings 4 Damage pitting Replace EAS23380 INSTALLING THE SWINGA...

Page 192: ...Install Pivot shaft nut 1 NOTE Lubricant the pivot shaft nut threads and mat ing surfaces with lithium soap based grease 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 2...

Page 193: ...71 EAS23400 CHAIN DRIVE Removing the drive chain Order Job Parts to remove Q ty Remarks Swingarm Refer to SWINGARM on page 4 66 1 Drive chain guard 1 2 Drive chain 1 For installation reverse the remov...

Page 194: ...the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check Drive chain Stiffness Clean and lubricate or replace 3 Clean Drive chain a Wipe the drive ch...

Page 195: ...KET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 18 EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4 18 EAS23490 INSTALLING THE DRIV...

Page 196: ...t Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 CAUTION ECA13550 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can...

Page 197: ...CHAIN DRIVE 4 75...

Page 198: ...ND VALVE GUIDES 5 23 CHECKING THE VALVE SEATS 5 25 CHECKING THE VALVE SPRINGS 5 27 CHECKING THE VALVE LIFTERS 5 28 INSTALLING THE VALVES 5 28 GENERATOR 5 30 REMOVING THE GENERATOR 5 32 INSTALLING THE...

Page 199: ...CKING THE OIL NOZZLES 5 61 ASSEMBLING THE OIL PUMP 5 62 INSTALLING THE OIL WATER PUMP ASSEMBLY 5 62 INSTALLING THE OIL PAN 5 63 CRANKCASE 5 65 DISASSEMBLING THE CRANKCASE 5 67 CHECKING THE CRANKCASE 5...

Page 200: ...CHECKING THE TRANSMISSION 5 90 INSTALLING THE TRANSMISSION 5 91...

Page 201: ...ks Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 26 1 Locknut 2 2 Shift rod 1 3 Sift arm 1 4 Drive sprocket cover 1 5 Drive...

Page 202: ...age 4 1 Lower cowlings Refer to GENERAL CHASSIS on page 4 1 1 Right footrest bracket 1 2 Protector cover 1 3 Protector 1 4 EXUP valve pulley cover 1 5 EXUP cable 2 6 EXUP servo motor bracket 1 7 EXUP...

Page 203: ...ENGINE REMOVAL 5 3 For installation reverse the removal proce dure Removing the exhaust pipe Order Job Parts to remove Q ty Remarks...

Page 204: ...lve pipe Order Job Parts to remove Q ty Remarks 1 Washer 1 2 Pulley 1 3 Collar 1 4 Plate 1 5 Spring 1 6 EXUP pulley bracket 1 7 Housing 1 8 Gasket 1 9 Collar 1 10 Shaft arm 1 11 Exhaust valve pipe 1 F...

Page 205: ...on page 6 4 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 Starter motor Refer to ELECTRIC STARTER on page 5 39 1 Battery negative lead 1 2 Battery positive lead 1 3 Clutch cable 1 4 Engi...

Page 206: ...ine mount collar outer 1 3 Engine mount collar center 1 4 Engine mount collar inner 1 5 Engine mounting bolt front left side 1 6 Locknut 1 7 Engine mounting bolt rear lower side 1 8 Locknut 1 9 Engine...

Page 207: ...mount bolt front left side 1 temporary tighten 5 Install Engine mount collar inner 1 Engine mount collar center 2 Engine mount collar outer 3 Right front engine mount bolt 4 temporary tighten 6 Tighte...

Page 208: ...t 8 Tighten Left front engine mounting bolt 1 9 Tighten Right front engine mounting bolt 1 Upper locknut 51 Nm 5 1 m kg 37 ft lb Lower locknut 51 Nm 5 1 m kg 37 ft lb Engine mounting bolt front left s...

Page 209: ...Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page 7 4 Radiator assembly Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 1 I...

Page 210: ...POSITION SEN SOR on page 5 37 1 Camshaft sprocket bolt 4 Loosen 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 3 5 Dowel pin 6 6 Exhaust camshaft cap 3 7 Dowel pin...

Page 211: ...OTE TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen Camshaft sprocket bolts 1 4 Remove Timing chain tensioner 1 Gasket 5 Remove Camshaft cap...

Page 212: ...amshaft caps NOTE Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring the camshaft journal to camshaft cap clea...

Page 213: ...the camshaft sprocket and the timing chain as a set EAS23950 CHECKING THE TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides 1 Check Timing ch...

Page 214: ...ring and timing chain tensioner rod 1 b Squeeze the timing chain tensioner clip 2 and push the timing chain tensioner rod 3 NOTE When the timing chain tensioner rod 3 is pushed while holding the grip...

Page 215: ...sure the punch mark a on each cam shaft faces up 4 Install Dowel pins Intake camshaft caps Exhaust camshaft caps NOTE Make sure each camshaft cap is installed in its original place Refer to the identi...

Page 216: ...aft punch mark a and the camshaft cap arrow mark b 8 Install Gasket Timing chain tensioner 1 Timing chain tensioner bolts 2 CAUTION ECA4C81006 The arrow mark a on the timing chain ten sioner should fa...

Page 217: ...CAMSHAFTS 5 17 11 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE on page 3 4 12 Install Pickup coil rotor cover CRANKSHAFT POSITION SENSOR on page 5 37...

Page 218: ...rks Engine Refer to ENGINE REMOVAL on page 5 1 Intake camshaft Refer to CAMSHAFTS on page 5 9 Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 4...

Page 219: ...um valves with the cylinder head Refer to CHECKING THE VALVE SEATS on page 5 25 Cylinder head water jacket Mineral deposits rust Eliminate 3 Measure Cylinder head warpage Out of specification Resurfac...

Page 220: ...0 m kg 29 ft lb with a torque wrench Final tighten the nuts 7 10 to 55 Nm 5 5 m kg 40 ft lb with a torque wrench Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the...

Page 221: ...8 3 Intake valve cotter 16 4 Intake valve upper spring seat 8 5 Intake valve spring 8 6 Intake valve oil seal 8 7 Intake valve lower spring seat 8 8 Intake valve 8 9 Intake valve guide 8 10 Exhaust va...

Page 222: ...VALVES AND VALVE SPRINGS 5 22 For installation reverse the removal proce dure Removing the valves and valve springs Order Job Parts to remove Q ty Remarks...

Page 223: ...Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the valve seat 1 3 Remove Valve cotters 1 NOTE Remove the valve cotte...

Page 224: ...e installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replac...

Page 225: ...ts 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head...

Page 226: ...ves with new valves NOTE When replacing the cylinder head replace the valves without lapping the valve seats and valve faces When replacing the valves or valves guides use new valves to lap the valve...

Page 227: ...lve seat EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Valve spring free length a Out of specification Replace the valve spring 2 Measure Co...

Page 228: ...Install Valve 1 Lower spring seat 2 Valve stem seal 3 Valve spring 4 Upper spring seat 5 into the cylinder head NOTE Make sure each valve is installed in its origi nal place Refer to the following em...

Page 229: ...e Valve pad 1 Valve lifter 2 with the recommended lubricant 7 Install Valve pad Valve lifter NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be...

Page 230: ...ge 4 1 Side cowlings Refer to GENERAL CHASSIS on page 4 1 Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Stator coil assembly coup...

Page 231: ...1 12 Stator coil assembly lead holder 1 13 Idler gear 1 14 Idler gear shaft 1 15 Washer 1 16 Bearing 1 For installation reverse the removal proce dure Removing the generator Order Job Parts to remove...

Page 232: ...Generator rotor and starter clutch assem bly 1 3 Remove Idle gear shaft bolt 1 Idle shaft Idle gear 2 EAS24500 INSTALLING THE GENERATOR 1 Install Idle gear shaft Idle gear 1 Washer Idle gear shaft bo...

Page 233: ...GENERATOR 5 33 NOTE First tighten the M8 bolts and then tighten the M6 bolts Tighten the generator rotor cover bolts in stages and in a crisscross pattern...

Page 234: ...Removing the starter clutch Order Job Parts to remove Q ty Remarks 1 Generator rotor 1 2 Damper 3 3 Driven gear 1 4 Washer 1 5 Starter clutch drive gear 1 6 Collar 1 7 Washer 1 8 Spacer 1 9 O ring 1...

Page 235: ...wear Replace EAS24570 CHECKING THE STARTER CLUTCH 1 Check Starter clutch rollers 1 Damage wear Replace 2 Check Starter clutch idle gear 1 Starter clutch drive gear 2 Burrs chips roughness wear Replac...

Page 236: ...wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS24600 INSTALLING THE STARTER CLUTCH 1 Install Generator rotor 1 Damper 2 Driven gear 3 NOTE The hole side of...

Page 237: ...4 1 Side cowlings Refer to GENERAL CHASSIS on page 4 1 Lower cowlings Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL o...

Page 238: ...each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them EAS24540 INSTALLING THE CRANKSHAFT POSITION SENSOR 1 Install Gasket Pickup...

Page 239: ...ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Throttle body Refer to THROTTLE BODIES on page...

Page 240: ...starter motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 Gasket 2 8 Brush holder 1 9 Rear cover 1 For...

Page 241: ...s commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the...

Page 242: ...holder and push the brush inside until it touches the armature 2 Install O rings Rear cover 1 NOTE Align the tab a on the brush holder 2 with the tab b in the starter motor rear cover 3 Install Nut 1...

Page 243: ...R 5 43 EAS24810 INSTALLING THE STARTER MOTOR 1 Install Starter motor 1 Starter motor bolts 2 2 Connect Starter motor lead 3 Starter motor bolt 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead bolt 7 Nm 0 7...

Page 244: ...Refer to GENERAL CHASSIS on page 4 1 Bottom cowlings Refer to GENERAL CHASSIS on page 4 1 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 1 Cover 1 2 Clutch cable 1 Disconnect 3 Clutch...

Page 245: ...Removing the push lever shaft Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal...

Page 246: ...e 1 1 6 Clutch plate 1 1 7 Friction plate 2 7 8 Clutch plate 2 1 9 Clutch plate 3 6 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Muffler 1 14 Spring 3 15 Clutch bo...

Page 247: ...ompression springs Pressure plate 2 Push rod 3 3 Remove Friction plate 1 1 4 Remove Clutch plate 1 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 3 Clutch damper spring Clutch damper...

Page 248: ...ge Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set 3 Measure assembly width a of th...

Page 249: ...tch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch hous ing NOTE Pitting on the clutch housi...

Page 250: ...r shaft pinion gear teeth 1 Push rod teeth 2 Damage wear Replace the push rod and push lever shaft pinion gear as a set 2 Check Push rod bearing Damage wear Replace EAS25240 INSTALLING THE CLUTCH 1 In...

Page 251: ...ch boss nut by staking them with a drift punch at the point aligned with the groove in the axle 4 Install Clutch damper spring seat 1 Clutch damper spring 2 NOTE Install the clutch damper spring as sh...

Page 252: ...l Push lever NOTE Install the push lever with the h mark facing toward upper side 11 Install Clutch cover Clutch cover gasket NOTE Install the push rod so that the teeth a face towards the rear of the...

Page 253: ...NOTE Tighten the clutch cover bolts in a stages and in a crisscross pattern 13 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY on page 3 14 Clutch cover bolt 12 Nm 1 2 m k...

Page 254: ...m Refer to ENGINE REMOVAL on page 5 1 Clutch assembly Refer to CLUTCH on page 5 44 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Collar 1 5 Shift shaft spring 1 6 Washer 1 7 Stopper screw 1 8 Stopper lever...

Page 255: ...ar Washer 5 Remove Stopper lever spring 1 Stopper screw 2 Stopper lever 3 Washer EAS25420 CHECKING THE SHIFT SHAFT 1 Check Shift shaft 1 Bends damage wear Replace Shift lever spring 2 Collar 3 Damage...

Page 256: ...with the shift drum segment assembly Lubricate the oil seal lips with lithium soap base grease Install the end of the shift shaft spring onto the shift shaft spring stopper 3 Install Washer 1 Circlip...

Page 257: ...o ENGINE REMOVAL on page 5 1 O2 sensor Refer to ENGINE REMOVAL on page 5 1 Muffler Refer to ENGINE REMOVAL on page 5 1 Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5 1 Clutch assembly Refer t...

Page 258: ...pump assembly drive chain guide 1 13 Collar 1 14 Oil water pump assembly drive sprocket 1 15 Washer 1 16 Oil water pump assembly drive chain 1 17 Dowel pin 1 18 Oil water pump assembly 1 For installat...

Page 259: ...pump Order Job Parts to remove Q ty Remarks 1 Oil water pump driven sprocket 1 2 Collar 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For assembl...

Page 260: ...n and oil water pump assembly drive sprocket as a set EAS24960 CHECKING THE OIL PUMP 1 Check Oil pump driven gear 1 Oil pump housing 2 Cracks damage wear Replace the defective part s 2 Measure Inner r...

Page 261: ...Y PIPES The following procedure applies to all of the oil delivery pipes 1 Check Oil delivery pipe 1 Oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EAS24990 CHECKING THE O...

Page 262: ...ter pump driven sprocket 1 NOTE 5VY mark of the oil water pump driven gear is installed at oil pump side 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 60 EAS25030 INSTALLING THE...

Page 263: ...ump assembly drive chain guide is upward 4 Install Oil delivery pipe 1 5 Install Relief valve 1 O ring Oil strainer 2 O ring Oil pipe 3 O ring Drain pipe 4 O ring EAS25050 INSTALLING THE OIL PAN 1 Ins...

Page 264: ...rain bolt WARNING EWA12820 Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch O ring with engine oil Engine oil drain bol...

Page 265: ...AD on page 5 18 Generator Refer to GENERATOR on page 5 30 Starter clutch Refer to STARTER CLUTCH on page 5 34 Shift shaft Refer to SHIFT SHAFT on page 5 54 Crankshaft position sensor Refer to CRANKSHA...

Page 266: ...CRANKCASE 5 66 7 Lower crankcase 1 8 Dowel pin 3 9 Damper 1 For installation reverse the removal proce dure Separating the crankcase Order Job Parts to remove Q ty Remarks...

Page 267: ...crankcase halves separate evenly 4 Remove Dowel pins 5 Remove Crankshaft journal lower bearing from the lower crankcase NOTE Identify the position of each crankshaft journal lower bearing so that it c...

Page 268: ...1 10 and 22 Seal bolt 18 Tighten the bolts in the tightening sequence cast on the crankcase M9 105 mm 4 1 in bolts 1 10 M8 60 mm 2 4 in bolt 11 LOCTITE M8 60 mm 2 4 in bolts 12 16 M8 50 mm 2 0 in bolt...

Page 269: ...ks Lower crankcase Refer to CRANKCASE on page 5 65 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 8 Top rin...

Page 270: ...on page 5 65 Connecting rod and connecting rod caps Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearin...

Page 271: ...3 CAUTION ECA4C81008 Do not use a hammer to drive the piston pin out NOTE For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the pist...

Page 272: ...as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set EAS24430 CHEC...

Page 273: ...ton pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston Piston ring side clearance Top ring 0 030 0 065 mm 0...

Page 274: ...ng rod and the big end lower bear ing into the connecting rod cap NOTE Align the projections a on the big end bear ings with the notches b in the connecting rod and connecting rod cap c Put a piece of...

Page 275: ...chined face a Thrusting faces 4 places at front and rear b NOTE To install the big end bearing care should be taken not to install it at an angle and the posi tion should not be out of alignment j Loo...

Page 276: ...lt until it is at the specified angles q Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 71 r Measure the compressed Plastigauge width on the...

Page 277: ...e that the Y mark a on the con necting rod faces left when the arrow mark b on the piston is pointing up as shown Reinstall each piston into its original cylinder numbering order starting from the lef...

Page 278: ...connecting rod bolts c After installing the big end bearing assem ble the connecting rod and connecting rod cap once using a single unit of the connect ing rod d Tighten the connecting rod bolt while...

Page 279: ...ing angle method a Clean the connecting rod bolts b Tighten the connecting rod bolts c Put a mark 1 on the connecting rod bolt 2 and the connecting rod cap 3 d Tighten the bolt further to reach the sp...

Page 280: ...OURNAL BEARINGS 1 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings CAUTION ECA4C81011 Do not interchange the crankshaft...

Page 281: ...s 12 16 M8 50 mm 2 0 in bolts 13 15 M6 65 mm 2 5 in bolts 17 18 M6 70 mm 2 8 in bolts 19 21 23 M6 50 mm 2 0 in bolts 20 26 M6 60 mm 2 4 in bolt and washer 22 M6 60 mm 2 4 in bolts 24 25 Following the...

Page 282: ...gs If the size is the same for all J1 to J5 one digit for that size is indicated Crankcase side only For example if the crankcase J1 and crankshaft web J1 numbers are 6 and 2 respectively then the bea...

Page 283: ...th the notches b in the upper crankcase Be sure to install each crankshaft journal upper bearing in its original place 3 Install Crankshaft 4 Install Crankcase lower Refer to CRANKCASE on page 5 65 5...

Page 284: ...Separate Refer to CRANKCASE on page 5 65 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Washer 1 6 Shift fork guide bar retainer 2 7 Spring 2 8 Shift fork guide bar 2 9 Shift fork L 1...

Page 285: ...TRANSMISSION 5 85 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks...

Page 286: ...pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar...

Page 287: ...Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8 Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6...

Page 288: ...TRANSMISSION 5 88 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks...

Page 289: ...Tighten the bolts until they contact the crankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil pipe 1 Bearing 2 EAS26260 CHECK...

Page 290: ...Damage pitting Replace the shift drum assembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Meas...

Page 291: ...t forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle 3 Install Shift fork L 1 and R 2 Drive axl...

Page 292: ...TRANSMISSION 5 92 4 Check Transmission Rough movement Repair NOTE Oil each gear shaft and bearing thoroughly...

Page 293: ...TRANSMISSION 5 93...

Page 294: ...6 4 CHECKING THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 CHECKING THE THERMOSTAT 6 7 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 8 INSTALLING THE THERMOSTAT ASSEMBLY 6 8 WATER PUMP 6 9 D...

Page 295: ...Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Radiator fan coupler 2 Disconnect 2 Fuse holde...

Page 296: ...RADIATOR 6 2 11 Radiator fan motor 2 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks...

Page 297: ...p tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Ref...

Page 298: ...ge 3 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 19 1 Oil cooler inlet hose 1 2 Oil cooler bolt 1 Loosen 3 Washer 1 Disconnect 4 Oil cooler 1 Disconnect 5 O ring 1 6 Water pump outlet pip...

Page 299: ...NOTE Before installing the oil cooler lubricate the oil cooler bolt and O ring with a thin coat of engine oil Make sure the O ring is positioned properly Align the projection a on the oil cooler with...

Page 300: ...page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to GENERAL CHASSIS on page 4 1 Coolant Refer to CHANGING THE COOLANT on page 3 19 1 Thermostat assembly outlet hose 1 2 Thermos...

Page 301: ...water b Slowly heat the water 3 c Place a thermometer 4 in the water d While stirring the water observe the ther mostat and thermometer s indicated tem perature Disassembling the thermostat assembly...

Page 302: ...EM BLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 NOTE Install the thermostat with its breather hole a facing up EAS26480 INSTALLING THE THERMOSTAT ASSEM BLY 1 Fil...

Page 303: ...Remarks Oil water pump assembly Refer to OIL PUMP on page 5 57 Oil pump rotor Refer to OIL PUMP on page 5 57 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impeller 1 5 Water...

Page 304: ...rewdriver NOTE Do not scratch the impeller shaft EAS26540 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Water pump housing 2 Impeller shaft 3 Rubber damper 4 Rubber damper holder 5 Water...

Page 305: ...ap water or coolant onto its outer surface 4 Measure Impeller shaft tilt Out of specification Repeat steps 3 and 4 CAUTION ECA14090 Make sure the rubber damper and rubber damper holder are flush with...

Page 306: ...NG THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODIES 7 4 CHECKING THE INJECTORS 7 6 CHECKING THE THROTTLE BODIES 7 6 CHECKING THE FUEL PRESSURE 7 6 ADJUSTING THE THROTTLE POSITION SENSOR...

Page 307: ...S on page 4 1 Passenger seat Refer to GENERAL CHASSIS on page 4 1 1 Fuel tank side cover 2 2 Fuel sender coupler 1 3 Fuel pump coupler 1 4 Fuel tank drain hose 1 5 Fuel tank breather hose 1 6 Fuel hos...

Page 308: ...on surface of the fuel pump is directly under the tank Be sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump CAUTION ECA14720 Do not drop the fuel pum...

Page 309: ...stalled NOTE Install the fuel hose connector securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose To install the fuel hose from the fuel injection...

Page 310: ...coupler 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Throttle servo motor coupler 1 Disconnect 4 Throttle position sensor for throttle valves cou pler 1 Disconnect 5 Throttle posi...

Page 311: ...1 Disconnect 4 Cylinder 3 injector coupler 1 Disconnect 5 Cylinder 4 injector coupler 1 Disconnect 6 Sub wire harness 1 7 Negative pressure hose 1 Disconnect 8 Intake air pressure sensor 1 9 Fuel dist...

Page 312: ...i mary injector fuel rail 1 from the primary injector fuel rail WARNING EWA4C81001 Cover fuel hose connections with a cloth when disconnecting them Residual pres sure in the fuel lines could cause fue...

Page 313: ...sor for throttle cable pulley Refer to ADJUSTING THE THROTTLE POSITION SENSOR FOR THROTTLE CABLE PULLEY on page 7 7 2 Adjust Throttle position sensor for throttle cable pulley angle a Temporary tighte...

Page 314: ...THROTTLE BODIES 7 8...

Page 315: ...Parts to remove Q ty Remarks 1 Air cut off valve coupler 1 Disconnect 2 Air cut off valve hose 1 1 Disconnect 3 Air cut off valve hose 2 1 Disconnect 4 Air cut off valve hose 3 1 Disconnect 5 Air cut...

Page 316: ...to allow the air to flow during idle and closes to cut off the flow when the vehicle is being driven However if the coolant tempera ture is below the specified value the air cut off valve remains open...

Page 317: ...AIR INDUCTION SYSTEM 7 11...

Page 318: ...UBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 26 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 FAIL SAFE ACTIONS SUBSTITUTE CHARACTER...

Page 319: ...TATOR COIL 8 93 CHECKING THE RECTIFIER REGULATOR 8 93 CHECKING THE HORN 8 94 CHECKING THE OIL LEVEL SWITCH 8 94 CHECKING THE FUEL SENDER 8 95 CHECKING THE SPEED SENSOR 8 95 CHECKING THE RADIATOR FAN M...

Page 320: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...

Page 321: ...Neutral switch 14 Sidestand switch 19 ECU engine control unit 20 Ignition coil 1 21 Ignition coil 2 22 Ignition coil 3 23 Ignition coil 4 24 Spark plug 35 Crankshaft position sensor 40 Lean angle sens...

Page 322: ...85 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 9 Re gap or replace the spark plugs 4 Check the ignition spark gap R...

Page 323: ...page 8 81 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the clutch switch 12 Check the starting circuit cut off relay Refer to CHECKING T...

Page 324: ...ELECTRIC STARTING SYSTEM 8 5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...

Page 325: ...tch 4 Main fuse 8 Battery 10 Starter relay 11 Starter motor 12 Starting circuit cut off relay 13 Neutral switch 14 Sidestand switch 58 Engine stop switch 59 Start switch 64 Clutch switch 79 Ignition f...

Page 326: ...ed The clutch lever is pulled to the handlebar the clutch switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from ope...

Page 327: ...D THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Starting circuit cut off relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Ne...

Page 328: ...tery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE STARTER MOTOR OPERATION on page 8 93 Repair or replace the starter motor 4 Check the starter mo...

Page 329: ...ck the sidestand switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the sidestand switch 11 Check the clutch switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the clutch switch 12 Che...

Page 330: ...CHARGING SYSTEM 8 11 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM...

Page 331: ...CHARGING SYSTEM 8 12 2 AC magneto 3 Rectifier regulator 4 Main fuse 8 Battery 88 Ground 89 Battery negative lead...

Page 332: ...tery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 93 Replace...

Page 333: ...CHARGING SYSTEM 8 14...

Page 334: ...LIGHTING SYSTEM 8 15 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM...

Page 335: ...U engine control unit 51 High beam indicator light 54 Meter light 62 Dimmer switch 71 Headlight 72 Auxiliary light 74 License plate light 76 Tail brake light 77 Headlight relay on off 78 Headlight rel...

Page 336: ...eadlight and park Refer to CHECKING THE FUSES on page 8 85 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replac...

Page 337: ...adlight relay dimmer Refer to CHECKING THE RELAYS on page 8 88 Replace the headlight relay 9 Check the entire lighting system s wiring Refer to LIGHTING SYSTEM on page 8 15 Properly connect or repair...

Page 338: ...SIGNALING SYSTEM 8 19 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM...

Page 339: ...ft timing indicator light 48 Multi function meter 50 Coolant temperature indicator light 52 Left turn signal indicator light 53 Right turn signal indicator light 57 Front brake light switch 60 Turn si...

Page 340: ...to CHECKING THE FUSES on page 8 85 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check th...

Page 341: ...t or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on pa...

Page 342: ...em s wiring This circuit is OK 1 Check the neutral switch Refer to CHECKING THE SWITCHES on page 8 81 Replace the neutral switch 2 Check the entire signaling system s wiring Refer to SIGNALING SYSTEM...

Page 343: ...e 8 19 Properly connect or repair the signal ing system s wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 8 95 Replace the speed sensor 2 Check the entire...

Page 344: ...COOLING SYSTEM 8 25 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM...

Page 345: ...ition and radiator fan motor Refer to CHECKING THE FUSES on page 8 85 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharg...

Page 346: ...COOLING SYSTEM 8 27 NG OK 7 Check the entire cooling system s wiring Refer to COOLING SYSTEM on page 8 25 Properly connect or repair the cooling system s wiring This circuit is OK...

Page 347: ...COOLING SYSTEM 8 28...

Page 348: ...FUEL INJECTION SYSTEM 8 29 EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM...

Page 349: ...U engine control unit 20 Ignition coil 1 21 Ignition coil 2 22 Ignition coil 3 23 Ignition coil 4 24 Spark plug 25 Injector 1 26 Injector 2 27 Injector 3 28 Injector 4 32 EXUP servo motor 33 Speed sen...

Page 350: ...fuel reservoir trip meter stop watch LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and FI system oper...

Page 351: ...ion sensor No normal signals are received from the cylinder identification sensor Malfunction of electric starting system Unable Able 12 Crankshaft position sensor No normal signals are received from...

Page 352: ...pending on the num ber of faulty cylinders 34 Ignition coil 2 faulty ignition Malfunction detected in the pri mary wire of the ignition coil 2 Able depending on the num ber of faulty cylinders Able de...

Page 353: ...tle position sensor for throttle cable pulley open or short circuit detected Throttle position sensor for throttle cable pulley coupler connection is loose Able Unable Able Unable 60 Throttle servo mo...

Page 354: ...not normal but the engine trouble warning light does not come on 1 Check the operation of following sensors and actuators in the Diagnostic mode Refer to Sensor operation table and Actuator operation...

Page 355: ...1 appears on the odometer trip meter fuel reservoir trip meter stop watch LCD 6 Set the engine stop switch to OFF 7 Select the diagnostic code number corresponding to the fault code number by pressing...

Page 356: ...ircuit in wire harness Defective intake air pressure sensor Malfunction in ECU 03 14 Intake air pressure sensor hose system malfunction clogged or detached hose Intake air pressure sensor hose is deta...

Page 357: ...ensor Malfunction in ECU 02 24 No normal signal is received from the O2 sen sor Open or short circuit in wire harness Defective O2 sensor Malfunction in ECU Improperly installed O2 sensor 30 Latch up...

Page 358: ...not appear on the meter Malfunction in ECU The program and data are not properly written on or read from the internal mem ory 59 Throttle position sensor for throttle cable pulley open or short circu...

Page 359: ...atmospheric pres sure with the meter display value 03 Intake air pressure Displays intake air pressure Compare the actually mea sured atmospheric pres sure with the meter display value without cranki...

Page 360: ...opened position 97 107 Check with throttle grip fully opened 15 Throttle position sensor for throttle cable pulley signal 2 Fully closed position 10 24 Check with throttle grip fully closed Fully ope...

Page 361: ...s 03 is displayed To erase the history set the engine stop switch from to 63 Malfunction code reinstate for fault code No 24 only No malfunction code 00 Malfunction code exists Fault codes 24 If more...

Page 362: ...el 36 Injector 1 Actuates the injector 1 five times at one second inter vals Illuminates the engine trou ble warning light Check the operating sound of the primary injector 1 five times 37 Injector 2...

Page 363: ...at one second intervals Illuminates the engine trou ble warning light The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Chec...

Page 364: ...2 Connections Cylinder identification sensor cou pler Main wire harness ECU coupler Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a ma...

Page 365: ...sor Replace if defective Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 8 92 Fault code No 13 Symptom Intake air pressure sensor open or short circuit detected Diagnostic code No 03 Intake a...

Page 366: ...ignal 2 Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of throttle position sensor for throttle valves Check for looseness or pinch ing C...

Page 367: ...vo motor potenti ometer circuit Execute the diagnostic mode Code No 53 Replace if defective Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Orde r Item compon...

Page 368: ...uit Between ECU coupler and relay unit coupler Blue Yellow Blue Yellow Between relay unit coupler and sidestand switch coupler Blue Black Blue Black Between sidestand switch cou pler and engine ground...

Page 369: ...Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 96 Fault code No 22 Symptom Air temperature sensor open or short circuit detecte...

Page 370: ...ective atmospheric pressure sen sor Execute the diagnostic mode Code No 02 Replace if defective Refer to CHECKING THE ATMOSPHERIC PRESSURE SENSOR on page 8 98 Fault code No 24 Symptom No normal signal...

Page 371: ...primary lead of the cylinder 1 ignition coil Diagnostic code No 30 Cylinder 1 ignition coil Orde r Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Cylind...

Page 372: ...e pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 2 igni tion coil cou pler 2 Open...

Page 373: ...ulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 3 igni tion coil cou pler 2 Open or...

Page 374: ...ut Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the cylinder 4 igni tion coil cou pler 2 Open or short c...

Page 375: ...d out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Connect the fuel injector couplers 2 Open or short circuit in...

Page 376: ...at may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Reinstated automatically if a normal signal is received 2 Open or s...

Page 377: ...or coupler and ECU coupler Blue Blue White Yellow White Yellow Black Blue Black Blue A 4 Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED...

Page 378: ...ler Red Red Between relay unit coupler and right handlebar switch coupler Red Black Red Black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No 09 Replace if defecti...

Page 379: ...short circuit in wire harness Repair or replace if there is an open or short circuit in the charging system s wiring Refer to CHARGING SYS TEM on page 8 11 Fault code No 50 Symptom Faulty ECU memory W...

Page 380: ...alled in the specified posi tion Turning the main switch to ON 2 Connections Throttle position sensor for throttle cable pulley coupler Main wire harness ECU coupler Check the couplers for any pins th...

Page 381: ...it in wire harness Repair or replace if there is an open or short circuit Between throttle servo motor coupler and ECU coupler Yellow Red Yellow Red Light green Red Light green Red 4 Defective throttl...

Page 382: ...er Yellow Blue Yellow Blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 3 Symptom Data from the ECU cannot be received correctly Dia...

Page 383: ...er assembly coupler Check the couplers for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the m...

Page 384: ...FUEL PUMP SYSTEM 8 65 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM...

Page 385: ...switch 4 Main fuse 8 Battery 9 Fuel injection system fuse 12 Starting circuit cut off relay 15 Fuel pump 19 ECU engine control unit 48 Multi function meter 58 Engine stop switch 79 Ignition fuse 88 Gr...

Page 386: ...the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 85 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 81 Rep...

Page 387: ...FUEL PUMP SYSTEM 8 68 NG OK 7 Check the entire fuel pump sys tem s wiring Refer to FUEL PUMP SYSTEM on page 8 65 Properly connect or repair the fuel pump system s wiring Replace the ECU...

Page 388: ...IMMOBILIZER SYSTEM 8 69 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM...

Page 389: ...M 8 70 1 Main switch 4 Main fuse 5 Backup fuse 6 Immobilizer unit 8 Battery 19 ECU engine control unit 42 Immobilizer system indicator light 48 Multi function meter 79 Ignition fuse 88 Ground 89 Batte...

Page 390: ...is lost reg istering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made...

Page 391: ...izer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator lig...

Page 392: ...gistration mode is acti vated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF rem...

Page 393: ...n nor flashes NG OK NG OK NG OK a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer syst...

Page 394: ...ys and antennas 2 Immobilizer unit mal function 3 Key malfunction 1 Keep magnets metal objects and other immobilizer system keys away form the keys and antennas 2 Replace the main switch immobi lizer...

Page 395: ...ion 4 ECU failure The ECU or immobi lizer unit was replaced with a used unit from another vehicle 1 Register the code re registering key 2 Check the wire harness and con nector 3 Replace the main swit...

Page 396: ...ELECTRICAL COMPONENTS 8 77 EAS27970 ELECTRICAL COMPONENTS...

Page 397: ...6 Starter relay 7 Battery 8 Main fuse 9 Neutral switch 10 Rear brake light switch 11 EXUP servo motor 12 Sidestand switch 13 O2 sensor 14 Speed sensor 15 Oil level switch 16 Ignition coil 17 Radiator...

Page 398: ...ELECTRICAL COMPONENTS 8 79...

Page 399: ...rn signal relay 7 ECU engine control unit 8 Lean angle sensor 9 Crankshaft position sensor 10 Intake air pressure sensor 11 Throttle servo motor 12 Throttle position sensor for throttle cable pulley 1...

Page 400: ...ELECTRICAL COMPONENTS 8 81 EAS27980 CHECKING THE SWITCHES...

Page 401: ...1 Main switch 2 Horn switch 3 Dimmer switch 4 Turn signal switch 5 Clutch switch 6 Sidestand switch 7 Engine stop switch 8 Front brake light switch 9 Start switch 10 Oil level switch 11 Neutral switch...

Page 402: ...o 0 and to the 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following examp...

Page 403: ...CAUTION ECA14380 Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head...

Page 404: ...ediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may ca...

Page 405: ...he charge state of the battery by measuring the specific gravity of the electro lyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Ri...

Page 406: ...urrent voltage charger a Measure the open circuit voltage prior to charging NOTE Voltage should be measured 30 minutes after the machine is stopped b Connect a charged and AMP meter to the battery and...

Page 407: ...ect properly 9 Lubricate Battery terminals 10 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester If the contin...

Page 408: ...terminal 3 Positive tester probe 4 Negative tester probe Result Continuity No continuity 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result...

Page 409: ...1 Negative tester probe Ground Pocket tester 90890 03112 Analog pocket tester YU 03112 C Continuity Positive tester probe Sky blue 1 Negative tester probe Black Yellow 2 No continuity Positive tester...

Page 410: ...il as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace a Disconnect the ignition coil leads from the ignition coil b Connect the pocket tester...

Page 411: ...nkshaft position sensor resistance EAS28130 CHECKING THE LEAN ANGLE SENSOR 1 Remove Lean angle sensor from the bracket 2 Check Lean angle sensor out put voltage Out of specification Replace a Connect...

Page 412: ...ce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect Stator coil coupler from the rectifier reg...

Page 413: ...the horn resistance 2 Check Horn sound Faulty sound Adjust or replace a Connect a battery 12 V to the horn b Turn the adjusting screw in direction a or b until the specified horn sound is obtained EAS...

Page 414: ...ensor coupler wire harness side as shown Oil level switch Maximum level position resis tance 484 536 at 20 C 68 F Minimum level position resis tance 114 126 at 20 C 68 F Pocket tester 90890 03112 Anal...

Page 415: ...le the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it 2 Check Coolant temperature se...

Page 416: ...istance 3 Install Throttle position sensor for throttle cable pulley NOTE When installing the throttle position sensor for throttle cable pulley adjust its angle properly Refer to ADJUSTING THE THROTT...

Page 417: ...tester 1 to the air induction system solenoid terminal as shown c Measure the air induction system solenoid resistance EAS28380 CHECKING THE ATMOSPHERIC PRES SURE SENSOR 1 Check Atmospheric pressure...

Page 418: ...s side as shown b Set the main switch to ON c Measure the intake air pressure sensor output voltage EAS28420 CHECKING THE INTAKE AIR TEMPERA TURE SENSOR 1 Remove Intake air temperature sensor from the...

Page 419: ...ake air temperature sensor resistance 3 Install Intake air temperature sensor Intake air pressure sensor resistance 2 21 2 69 k at 20 C 68 F Pocket tester 90890 03112 Analog pocket tester YU 03112 C P...

Page 420: ...ELECTRICAL COMPONENTS 8 101...

Page 421: ...ING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PER...

Page 422: ...inated fuel 2 Fuel pump Faulty fuel pump Faulty fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse...

Page 423: ...ft fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal positio...

Page 424: ...fluid level EAS28650 FAULTY FRONT FORK LEGS Leaking oil Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip Incorrect oil level high Loose...

Page 425: ...does not come on Too many electrical accessories Incorrect connection Tail brake light bulb burnt out Faulty battery Incorrectly adjusted rear brake light switch Turn signal does not come on Faulty tu...

Page 426: ...switch 56 Right handlebar switch 57 Front brake light switch 58 Engine stop switch 59 Start switch 60 Turn signal relay 61 Left handlebar switch 62 Dimmer switch 63 Horn switch 64 Clutch switch 65 Tu...

Page 427: ...B B L R B B L R B B L B B R L L W R B L W R Sb W B Y Sb L Y L B R W L Y L W B R W Br R W R B Dg Y Br W R Y Ch L Y B B Y Br Dg Y Br W R Y Ch L Y B B Y Br R OFF RUN FREE PUSH R N L Br W Br HI LO OFF ON...

Page 428: ...S D B HEADLIGHT SUB WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 6 2 3 1 5 79 82 80 81 83 85 78 87 86 84 77 75 61 63 65 64 66 67 68 69 70 54 54 53 52 35 36 37 38 39 40 33 32 51 50 49 48 47 46 45 44 43 42 4...

Page 429: ...Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto ON M2H 3B4...